engine – dismantle and assemble (21 134 8) - ford · pdf file2,5l tci diesel engine...

2,5l TCI Diesel Engine

10/96 Scorpio ’95 00-01-1

Engine – Dismantle and Assemble (21 134 8)Special Tools

15033

15–033Remover/installer,crankshaft main bearing

15072

15–072Oil seal remover

16067

16–067Locator for clutch disc

21002

21–002Splined head socket,cylinder head bolts

21003

21–003Cylinder head locating studs

21–037 B

21-037 BPilot bearing remover

21–044 A

21–044AInstaller/aligner, pilotbearing/clutch plate

21051

21–051Oil seal remover

21064

21–064Mounting bracket

21128

21–128Cylinder head guide studs

21150A

21–150AMounting plate

21153B

21–153BRemover for vibrationdamper

21168

21–168Crankshaft immobilising tool

21175

21–175Wrench for M14 cylinderhead bolts

21176

21–176Installer, radial oil seal

21177

21–177Flywheel locating studs

21178

21–178Installer, radial oil seal

21179

21–179Separator, sump

21181

21–181Remover, cylinder liner

21182

21–182Cylinder liner clamping bolts


10/96 Scorpio ’95 00-01-2

21183

21–183Measuring fixture, cylinderliner protrusion

21185

21–185Remover/installer,crankshaft main bearing

21186

21–186Crankshaft guide sleeve

21540

21–540Bolt tightening angle gauge

23018

23–018Dial indicator fixture for fuelinjection pump timing

23043

23–043Wrench for injectors

23044

23–044Remover, injection pumptiming pulley

24003

24–003Remover/installer, coolinghose clamp

Proprietary Tools

Oil filter wrench

Dial indicators

Magnetic fixture

Internal gauge

Micrometer screw 50 – 75 mm

Micrometer screw 75 – 100 mm

Piston ring compressor

T30 bit with 1/4” bit holder and extension

Workshop Equipment

Assembly stand

Workshop press

Materials

Plastigage Obtainable through:ReplacementServices Limited,30 Euston Street,Freemans IndustrialEstate, Leicester,LE2 7ST

Copper oil seals forinjectors: 1,5 mmthick, with an internaldiameter of 17,5 mm.

Obtainable through:Bosch authoriseddealerships

Adhesive Loctite 222 WSK-M2G351-A4

Engine Oil SAE 15W40

Lubricant Hypoid oil SAE90

Lubricant ESD-M1C220-A

Sealer SLM–4G9111–A

Sealer ESEAM–1C1014

Sealer SPM–2G9121–A

Adhesive WSK–M2G349–A7

D2103200

(

Dismantle

1. General note.

Use removal and fitting tool 24–003 toremove coolant and breather hoses ifnecessary.

2. Remove the left-hand engine mountingbracket.


10/96 Scorpio ’95 00-01-3

D2103095

1 2

NOTE: Watch out for escaping oil.

3. Detach the turbocharger oil return hose.

1 Detach the hose.

2 Remove the connector.

D2103106

NOTE: Escaping oil.

4. Remove the engine oil filter.

5. Remove the oil filter intermediatehousing.

D2103096

1

21–064

21–150

2

6. Mount the engine on an assembly stand.

1 Fit the mounting plate.

2 Fit the mounting bracket to the mountingplate.

Mount the engine on the assembly stand

S2103049

78 Nm

78 NmNOTE: Remove both oil drain plugs.

7. Drain off the engine oil.

Tighten the oil drain plugs with new oil sealsonce the engine oil has been removed.


10/96 Scorpio ’95 00-01-4

D2103201

8. Remove the right-hand engine mountingbracket.

1

D2103097

2 3

9. Remove the alternator with the vacuumpump.

1 Detach the vacuum pump oil return hose.

2 Detach the oil feed pipe.

3 Remove the alternator and vacuum pump.

S2103031

1

3 2

2

10. Detach the upper alternator bracket andthe lower fuel injection pump bracket.

1 Undo the nut and bolt on the injection pumpbracket.

2 Remove the alternator bracket.

3 Remove the engine lifting eye (one bolt).

S2103030

11. Remove the automatic belt tensioner.


10/96 Scorpio ’95 00-01-5

S2103070

2

1

4

3

12. Disconnect the hoses.

1 Crankcase ventilation hose.

2 Oil separator return hose.

3 Wiring loom retaining clamp.

4 Withdraw the oil dipstick.

IAS2103077

2

1

13. Disconnect the fuel return hose from theinjection pump.

1 Fuel return hose

2 Unclip the fuel pipes.

IAS2103090

31

2

4

14. Disconnect the plugs.

1 Engine coolant temperature (ECT) sensor.

2 Coolant temperature gauge sender

3 Remove the wiring loom retaining clamp.

4 Oil pressure switch.

Undo the cable ties.


10/96 Scorpio ’95 00-01-6

D2103010

4

3

5

2

1

15. Pull off the connectors and detach thewiring loom.

1 Plug of fuel shut-off valve.

2 Fuel level variable resistor (FLVR) sensorconnector

3 Fuel injection pump timing adjusting valveconnector.

4 Fuel heater connector.

5 Detach the wiring loom retaining clip fromthe accelerator bracket.

1

D2103011

2

16. Detach the connectors from the fuel filtermounting plate and disconnect them.

1 Crankcase position sensor (CKP sensor).

2 Fuel injector needle lift position sensor(NLS) connector.

2

D2103104

1

17. Detach the fuel filter mounting platecomplete with the fuel heater, oilseparator and wiring loom.

1 Detach the fuel feed pipe.

2 Detach the mounting plate with the oil feedpipe bracket.

18. Remove the wiring loom complete.

2

D21031051

19. Disconnect the vacuum pump oil feedpipe.

1 Oil feed pipe.

2 Oil feed pipe bracket.


10/96 Scorpio ’95 00-01-7

S2103062

NOTE: Escaping fuel. Close off the openings inthe injection pump and the injectors withsuitable plugs.

20. Remove the fuel injection pipes and pulloff the leak off hoses.

D2103015

21. Remove the smoke pressure limiter (SPL)pipe.

D2103107

22. Detach the coolant pipe bracket from thecylinder block.

S2103053

23. Disconnect the turbocharger oil feed pipefrom the main bearing housing hollowlocating screw.


10/96 Scorpio ’95 00-01-8

D2103020

2 124. Remove the exhaust manifold with the

turbocharger.

1 Detach the pipe flange from the exhaust gasrecirculation valve (EGR valve).

2 Remove the exhaust manifold.

1

D2103018

23

25. Remove the coolant pump.

1 Detach the coolant hose.

2 Withdraw the hose from the bracket.

3 Remove the bolts.

D2103021

26. Remove the intake manifold with the EGRvalve.

Take off the intake/exhaust manifold gasket.

D2103108

27. Remove the coolant collection tube withthe thermostat housing.

Take off the gaskets.


10/96 Scorpio ’95 00-01-9

PZS2103123

28. Remove the rocker arm oil feed pipe.

S2103032

29. Remove the cylinder head cover.

Take off the gasket.

D2103025

23–04330. Remove the injectors using the special

tool.

Cut through the old sealing rings andremove them.

S2103034

1

2

NOTE: Keep the rocker shafts and push rods inorder.

31. Remove the rocker shafts.

1 Rocker shafts.

2 Push rods.


10/96 Scorpio ’95 00-01-10

S2103078

4

3

1

2 6

5

8

7

21–002

NOTE: Bolt-slackening sequence.

32. Unscrew and remove the cylinder headouter bolts (M12).

21–17510

1

9

3

7

56

4

8

2

S2103079

NOTE: Bolt-slackening sequence.

NOTE: Keep the cylinder heads and endspacers in order.

33. Unscrew and remove the cylinder headinner bolts (M14) and thrust elements.

� Remove the end spacers on the side.

� Remove each cylinder head in turn workingfrom the flywheel end of the engine.

� Remove the cylinder head gaskets.


10/96 Scorpio ’95 00-01-11

S2103072

34. Remove the hydraulic tappets andaligning clips.

S2103073

2

21–168 1

35. Remove the idler pulley.

36. Remove the crankshaft pulley/vibrationdamper bolt.

NOTE: If necessary reverse the locking tooth ofthe immobilising tool.

1 Fit an immobilising tool.

2 Crankshaft pulley/vibration damper nut.

S2103054

21–153 A

37. Remove the crankshaft pulley/vibrationdamper.

D2103033

15–072

38. Remove the crankshaft front oil seal.


10/96 Scorpio ’95 00-01-12

D2103034

39. Unscrew and remove the timing coverbolts.

Remove the TDC mark and the hoseretaining clip.

D2103035

21–179

�CAUTION: Take care not to damage themating faces. The timing cover will be bentif any other tools are used.

40. Separate the timing cover from thecylinder block using the separator tool.

Remove any sealer residues.

D2103036

41. Remove the injection pump timing pulleynut.

D2103037

23–044

42. Remove the injection pump timing pulley.


10/96 Scorpio ’95 00-01-13

D2103038

43. Remove the injection pump.

D2103039

21

NOTE: The gear wheel is under springpressure. Movable vanes can drop out.

44. Remove the vacuum pump.

1 Remove the bolts.

2 Remove the vacuum pump connector.

D2103040

NOTE: The rotor can drop out.

45. Remove the oil pump.

D2103041

46. Remove the camshaft.

� Remove the camshaft thrust plate.

� Carefully pull the camshaft out of thecylinder block.


10/96 Scorpio ’95 00-01-14

D2103042

NOTE: Clutch disc.

47. Remove the clutch.

D2103043

48. Detach the crankshaft position (CKP)sensor.

D2103044

49. Remove the flywheel.

�CAUTION: Do not remove the flywheel yet.

� Remove the bolts.

� Remove the immobilising tool.

D2103577

21–177

50. Remove the flywheel (cont.).

� Screw in the flywheel guide studs.

� Remove the flywheel.

� Remove the flywheel guide studs.


10/96 Scorpio ’95 00-01-15

D2103045

1

221–051

51. Prise out the crankshaft rear oil seal.

1 Remove the thrust washers.

2 Prise out the oil seal.

21–037 B

D2103046

52. Remove the crankshaft pilot bearing.

D2103047

53. Remove the transmission intermediateflange with the oil seal housing and mainbearing housing.

D2103048

54. Remove the oil seal housing and mainbearing housing.


10/96 Scorpio ’95 00-01-16

IAS2103093

NOTE: Use a T30 bit, 1/4” bit holder andextension.

55. Detach the sump.

If the bolts are stiff, slacken them by tappingon them with a brass drift.

S2103033

56. Detach the sump (cont.).

S2103075

�CAUTION: Take care not to damage themating faces.

57. Separate the sump from the cylinderblock.

Remove any sealer residues.

IAS2103091

58. Remove the oil intake pipe and bracket.


10/96 Scorpio ’95 00-01-17

S2104026

�CAUTION: Take care not to damage thecylinder liners.

59. Remove the carbon from the upper edgesof the cylinder bores.

Remove the carbon ring from the top of thecylinder bore with a proprietary scraper.

D2103054

60. Remove the pistons.

NOTE: Keep the big-end bearing shells andcaps in order.

Remove the big-end bearing caps.

NOTE: Mark the pistons and cylinder liners.

Press out the pistons with the connectingrods and big-end bearing shells.

D2103055

21–186

61. Fit the guide sleeve.

S2103055

321

62. Remove the main bearing housing hollowlocating screws.

1 Remove the oil pressure switch.

2 Remove the oil feed connection.

�WARNING: Only slacken the hollow screw.

3 Slacken the hollow retaining screw.


10/96 Scorpio ’95 00-01-18

D2103057

63. Remove the main bearing housings.

�WARNING: Prevent the crankshaft fromdropping out with a block of wood.

� Move the engine block so that it is vertical.

� Mark the installed position of each mainbearing housing in relation to the cylinderblock using centre punch marks.

� Remove the hollow locating screw.

� Push the crankshaft through until the mainbearing housings are accessible.

� Turn the cylinder block until it is horizontal.

NOTE: Keep the main bearing housings andbearing shells in order.

Remove the main bearing housings.

D2103058

21–18664. Guide the crankshaft carefully out of the

cylinder block using the guide sleeve.

D2103059

65. Remove the pressure relief valve fromthe cylinder block.


10/96 Scorpio ’95 00-01-19

Y

X

A

10 mm

60 mm120 mm

A2101701

XY

B

66. Measure the cylinder liners.

� Clean the cylinder liners.

� Measure the cylinder liner bore at the top,in the middle and at the bottom using aproprietary internal gauge.

� Change the cylinder liners if necessary.

D2103061

21–181

67. Remove the cylinder liners.

NOTE: Mark the position of the cylinder liners inrelation to the cylinder block.

�CAUTION: Make absolutely certain that theextractor is correctly seated.

Withdraw the cylinder liners.


10/96 Scorpio ’95 00-01-20

Assemble

68. General note.

� When installing ventilation or coolanthoses use Special Tool 24-003 ifnecessary.

� All self-locking nuts, gaskets and sealsmust be renewed.

69. Preparations.

� Clean all the mating faces thoroughly.

� Clean the piston cooling oil spray nozzlesin the main bearing housings, the oilwaysand the pressure relief valve.

� Renew all seals and gaskets.

D2103562

21–183

NOTE: Measure the cylinder liner protrusionseparately for each cylinder.

70. Measure the cylinder liner protrusion anddetermine the required shim.

NOTE: The support and guiding surfaces of thecylinder liner and cylinder block must be free ofdirt and oil.

� Insert the cylinder liner without the shim andO-rings.

� Measure the difference between the cylinderliner and the cylinder block using the specialtool and a proprietary dial gauge.

� Choose a suitable shim according to thedifference and the specified oversize.

Available shims:0,15 mm0,17 mm0,20 mm0,23 mm0,25 mm


10/96 Scorpio ’95 00-01-21

D2103563

1

2

3

4

71. Fit the cylinder liners.

�CAUTION: Extreme care and cleanlinessare essential.Do not damage the shim.

1 Fit the cylinder liner with a suitable shim asmeasured in sub-operation 70.

2 Fit new O-rings.

3 Fit a new oil proof O-ring.

4 Apply adhesive (WSK–M2G351–A4) to theliner upper guiding surfaces on the cylinderliners.

Apply engine oil (SAE 15W40) to the lowerguiding surfaces for the cylinder liners onthe cylinder block.

NOTE: Note the position mark when refittingthe original cylinder liners.

Fit the cylinder liners.

21–182 30 Nm

PZS2103615

NOTE: The adhesive takes approx. two hoursto harden.

72. Clamp the cylinder liners.

Fit the cylinder liner pressure pieces withspecial bolts and tighten them.

D2103565

73. Measure the crankshaft main bearingshells in the cylinder block.

� Measure the bearing shells using aproprietary internal gauge.

� Renew the bearing shells as necessary (seesteps 74. to 75.).


10/96 Scorpio ’95 00-01-22

D2103066

21–185

74. Pull the main bearing shells out of thecylinder block.

21–185

D2103566

NOTE: The oil drillings in the main bearingshells and those in the bearing seats must lineup.Note the installation depth of the front face.

75. Draw the crankshaft main bearing shellsinto the cylinder block.

Measure the main bearing shells after theyhave been fitted (see step 73.).

D2103567

15–033

76. Measure the main bearing shell in the oilseal/bearing housing and renew it ifnecessary.

� Measure the main bearing shell asdescribed in step 73.

� Press out the main bearing shell using theremover/installer on a proprietary workshoppress.

� Press in the new main bearing shell usingthe same remover/installer on a proprietaryworkshop press.

� Measure the main bearing shell after it hasbeen fitted.


10/96 Scorpio ’95 00-01-23

42 Nm

D2103568

2

1

77. Measure the main bearing shells in theirhousings and renew them as necessary.

NOTE: There are notch marks. Do notassemble the main bearing housings back tofront.

1 Lay the main bearing shells dry in thehousing to which they belong and assemblethe housing.

2 Measure the bearing shells using aproprietary internal gauge.

Renew the bearing shells if necessary.

D2103569

78. Measure the camshaft bearing shells inthe cylinder block and renew them asnecessary.

PZS2103616

79. Measure the running surfaces of the mainbearing journals using a proprietarymicrometer.

Repeat the test at an angle of 90�.

D2103571

80. Measure the running surfaces of thecamshaft journals using a proprietarymicrometer.


10/96 Scorpio ’95 00-01-24

D2103059

81. Install the pressure relief valve in thecylinder block.

Coat the sliding faces of the valve withengine oil (SAE 15W40).

D2103558

21–18682. Insert the crankshaft.

� Coat all main bearing shells and bearingjournals with hypoid oil SAE90.

� Carefully guide the crankshaft into thecylinder block using the special tool.

D2103557

42 Nm

83. Install the main bearing housings.

NOTE: Notch marks on the main bearinghousing halves.

NOTE: Aim the piston cooling oil splash nozzlesat the preceding cylinder.

Fit the main bearing housings and theircorresponding lubricated main bearingshells.

NOTE: The hole in the main bearing housingmust point upwards; the notch marks must lineup.

Turn the bearing housings into position.


10/96 Scorpio ’95 00-01-25

D2103572

84. Fit the crankshaft in the cylinder block.

Turn the engine block so that it is vertical.

NOTE: The holes in the main bearing housingsmust line up with those for the hollow locatingbolts.

Install the main bearing housings using theirown weight and light blows from a brassdrift.

D2103556

147 Nm 347 Nm

247 Nm

85. Install the main bearing housing hollowlocating bolts.

NOTE: Use new seals.

1 Oil pressure switch.

2 Oil pressure connection.

3 Hollow locating screw

D2103555

21–186

86. Remove the guide sleeve.

A2101700

87. Check the piston ring gaps.

Renew the piston rings on reaching thespecified maximum wear.


10/96 Scorpio ’95 00-01-26

S2103584

1

2

32

88. Dismantle and assemble the pistonsand connecting rods.

NOTE: The piston pin “floats” in the piston andconnecting rod.

� Remove the circlips and drive the pistonpin out.

� Check that the pistons, piston pins andconnecting rods measurements are withinspecification and renew as necessary.

� Insert the piston pin in the piston andconnecting rod and fit the circlips.

1 Fit the trapezoid compression ring with theTOP marking uppermost.

2 Fit the stepped taper-faced ring with thestep pointing downwards.

3 Assemble and fit the oil control ring.

D2103574

89. Install the pistons.

� Lubricate the pistons and cylinder liner boreswith engine oil SAE 15W40.

� Spread the piston ring gaps evenly aroundthe circumference. This also applies to theelements of the oil control ring.

� Compress the piston rings using aproprietary piston ring compressor.

� Press the piston into the cylinder liner withthe handle of a hammer, guiding theconnecting rod onto the big-end bearingjournal.

NOTE: The combustion chamber in the pistonand the matching numbering on the connectingrod should face towards the camshaft side.

Make sure the bearing shells are clean anddry and place them in the connecting rod.


10/96 Scorpio ’95 00-01-27

D2103575

90. Preparation for measuring the big-endbearing clearance.

NOTE: The following steps must be carried outexactly as described.

� Measure each big-end bearing areaseparately with a length of Plastigagethread.

� Only fit the bearing cap to be measured, andtighten it to the specified torque.

� The measurement should be made as closeas possible to the TDC position of thatbearing.

� The big-end bearing shells and journalsmust be clean and oil free.

� Lay a length of Plastigage thread across thebearing journal.

D2103554

29 Nm

21–540

6091. Measure the big-end bearing clearance.

Install the big-end bearing cap with thematching bearing shells as described in step90. and torque it down in two stages.

NOTE: The numbers on the connecting rod andbearing cap must match and must both pointtowards the camshaft side.

Remove the big-end bearing cap.

D2103576

92. Compare the width of Plastigage threadwith the Plastigage scale.

� The scale reading corresponds to thebearing clearance.

� Renew the big-end bearing shells andregrind the bearing journals as necessary.


10/96 Scorpio ’95 00-01-28

D2103554

29 Nm

21–540

60NOTE: The corresponding numbers on theconnecting rods and the bearing caps pointtowards the camshaft side.

93. Fit the big-end bearing caps.

� Coat the big-end bearing shells and journalswith hypoid oil SAE90.

� Tighten the big-end bearing shells and thematching bearing shells in two stages.

IAS2103576

27 Nm

NOTE: The correct seating of the two O-rings.

94. Install the oil intake pipe and bracket.

D2103548

12 Nm

NOTE: The position of the piston cooling oilsplash nozzle is determined by the location ofthe holes for the retaining bolts.

95. Fit the oil seal and main bearing housingto the transmission flange.

S2103583

96. Fit the sump.

� Apply sealer (SLM–4G9111–A) to thecylinder block.

� Locate the sump in place and tighten thebolts finger tight.


10/96 Scorpio ’95 00-01-29

PZS2103617

37 Nm

47 Nm

27 Nm

27 Nm97. Fit the transmission intermediate flange

with the oil seal/main bearing housing.

� Fit new O-rings for the oil seal/main bearinghousing and the camshaft bearing.

� Apply lubricant (ESD–M1C220–A) to thecamshaft bearings and O-rings.

� Centre the transmission intermediate flangewith locating sleeves and secure it.

S2103533

1

3

4

5

6

2

3

4

5

6

2

12 Nm

1

9

7

108 8

NOTE: Tighten the bolts, working diagonallyfrom the centre outwards.

98. Tighten the sump bolts.

D2103546

21–044 A

99. Fit a new crankshaft pilot bearing.


10/96 Scorpio ’95 00-01-30

21–176

D2103545

NOTE: The sealing lip must remain dry.

NOTE: Apply engine oil SAE 15W40 to theouter edge of the oil seal.

100.Fit the crankshaft rear oil seal.

Draw in the new oil seal evenly using thetwo flywheel bolts and the special tool.

D2103577

21–177

101.Fit the flywheel.

� Coat the thrust washers with lubricant(ESD–M1C220–A) and place them in the oilseal/main bearing housing with thelubricating groove facing outwards.

� Screw in the guide studs.

NOTE: The locating sleeve and hole must lineup.

� Fit the flywheel in place using a new O-ring.

� Remove the guide studs.

21–168PZS2103618

20 Nm7521–540

21–168

102.Tighten the flywheel bolts.

� Engage the locking tool in the flywheel teeth.

� Coat the bolts with engine oil SAE 15W40and screw them in working diagonally.

� Tighten the bolts in two stages workingdiagonally.

D2103578

103.Check the crankshaft end float.

� Set up a dial indicator.

� Measure the end float by lifting the flywheelas shown.

� Adjust the end float as necessary usingthrust washers at the oil seal/main bearinghousing.


10/96 Scorpio ’95 00-01-31

D2103543

12 Nm

104.Fit the CKP sensor with a new O-ring.

M1601514

16–067

105.Centre the clutch disc on the pressureplate.

PZS2103624

27 Nm

16–067

106.Fit the clutch.

� Fit the clutch pressure plate with the centredclutch disc.

� Tighten the bolts uniformly, workingdiagonally.

� Remove the centring tool.

D2103541

29 Nm

107. Install the camshaft.

� Coat the camshaft bearing and runningsurfaces with hypoid oil SAE 90.

� Carefully guide the camshaft into thecylinder block.

� Secure the camshaft in the cylinder blockwith the thrust plate.


10/96 Scorpio ’95 00-01-32

D2103579

108.Check the camshaft end float.

� Set up a dial indicator.

� Measure the end float by lifting the camshaftwith a screwdriver.

� Adjust the end float as necessary byrenewing the thrust plate.

D2103540

27 Nm

109.Fit the oil pump.

� Fit a new O-ring and oil it lightly.

NOTE: Install the rotor with the dot markpointing towards the pump.

� Coat the oil pump shaft with hypoid oilSAE 90 and fit the oil pump.

D2103539

21 Nm

2

54 Nm

1110. Install the vacuum pump.

Lightly oil the internal moving parts of thevacuum pump and coat the vacuum pumppivot pin with hypoid oil SAE 90.

NOTE: The teeth on the crankshaft, vacuumpump and camshaft gear wheels must bealigned so that each single dot is in between thecorresponding two dots.

1 Install the vacuum pump using a new, lightlyoiled O-ring.

2 Fit the vacuum pump connector with newseals.


10/96 Scorpio ’95 00-01-33

D2103038

111. Fit the injection pump.

NOTE: The key on the fuel-injection pump shaftmust be at eleven o’clock.Fit the gearwheel so that the injection pumpshaft can be turned.

Put the injection pump in place using a newgasket and tighten the nuts finger tight.

D2103536

88 Nm

112. Fit the injection pump gear wheel.

NOTE: The tooth with the B mark on theinjection pump gear wheel must be exactly inbetween the two dot marks on the camshaftgear wheel.

Coat the timing gears with hypoid oilSAE 90.

S2103573

2

12 Nm 1

113. Fit the timing case with the TDC markand the hose retaining clip.

� Apply sealer (SPM–2G9121–A) thinly to thecylinder block mating face.

1 Bolts M6

2 Bolt M8

D2103533

21–178

NOTE: Fit the seal dry.

114. Fit the crankshaft front oil seal.


10/96 Scorpio ’95 00-01-34

S2103567

21–168 2

196 Nm

1

45 Nm115. Fit the idler pulley.

116. Fit the crankshaft pulley/vibrationdamper.

NOTE: Coat the crankshaft thread withadhesive (WSK–M2G349–A7).

1 Install the crankshaft pulley/vibrationdamper.

2 Remove the immobilising tool.

D2103580

23–018

21–183 2

1

NOTE: The fixed TDC mark on the timing coverand the movable TDC mark on the crankshaftvibration damper must be checked to ensurethat they are in the correct positions.

117. Preparations for adjusting the fuelinjection pump timing.

Unscrew the pump timing blanking plug.

1 Screw in the special tool with the dial gauge.

Turn the injection pump towards the cylinderblock.

2 Set the first cylinder to TDC using thespecial tool and the dial gauge.


10/96 Scorpio ’95 00-01-35

D2103581

21–183

NOTE: Bearing clearance. The crankshaftmust not be turned back to reach TDCposition.

118. Adjust the fuel-injection pump timing

Rotate the crankshaft backwards throughapproximately 45�.

NOTE: The pointer on the pump timing dialindicator must not move further.

� Zero the pump timing dial indicator.

� Turn the crankshaft forwards to TDCposition on the first cylinder.

D2103582

23–018

21–183

119. Adjust the fuel-injection pump timing(cont.).

� Turn the injection pump until the fuelinjection dial gauge reads 0,53 to 0,57 mm.

� Tighten the injection pump bolts.

� Check the setting at the fuel injection dialgauge by turning the crankshaft back andforth through the TDC position for the firstcylinder; repeat the setting procedure ifnecessary.

D2103610

1

30 Nm 2

120.Tighten the retaining nuts of thefuel-injection pump.

Detach the dial gauge bracket 23–018 anddial gauge.

1 Fit the blanking plug with a new oil seal.

2 Tighten the three retaining nuts of thefuel-injection pump.


10/96 Scorpio ’95 00-01-36

S2103082

21–182

NOTE: The adhesive used to stick the cylinderliners must have had two hours to harden.

121.Remove the cylinder liner thrustelements.

S2103072

122. Insert the hydraulic tappets and aligningclips.

Coat the tappets with engine oil SAE15W40.

D2103584

21–183

123.Measure the piston protrusion.

� Measure the piston protrusion of eachindividual cylinder at TDC using themeasuring fixture and dial gauge.

� Measure the difference between the pistoncrown and the cylinder block.

NOTE: One measurement should be made foreach cylinder on the axis of the piston pin at adistance of 5 mm from the edge of the piston.

The largest measurement determines thechoice of all four cylinder head gaskets:

Piston protrusion –> Thickness of cylinderhead gasket –> No. of notch marks

0.53 – 0,62 mm –>1,42 –>1

0,63 – 0,72 mm –>1,52 –>2

0,73 – 0,82 mm –>1,62 –> 0


10/96 Scorpio ’95 00-01-37

21–128

1

3

D2103585

2

21–003

124.Fit the cylinder head gaskets.

1 Fit the new cylinder head gaskets with theinscription facing upwards.

2 Gasket thickness marking.

3 Screw in the guide studs.

D2103586

221–128

21–003

1

125.Fit the cylinder heads.

NOTE: Make sure that the thrust elements arepositioned correctly. With used cylinder headstake the imprint as a guide.

� Fit the cylinder heads with the aid of thelocating studs.

� Coat the cylinder head bolt heads andthreads with hypoid oil SAE90.

1 Fit the end spacer.

2 Lay the thrust elements in place and screwin the inner M14 cylinder head bolts.


10/96 Scorpio ’95 00-01-38

D2103587

3

2

21–128

21–003 1126.Fit the cylinder heads (cont.).

NOTE: Make sure that the pressure pads arepositioned correctly.With used cylinder heads take the imprint as aguide.

Coat the cylinder head bolt heads andthreads with hypoid oil SAE90.

1 Transfer the locating studs and fit thecylinder heads.

2 Screw in the outer M12 cylinder head bolts.

3 Fit the end spacer.

� Lay the thrust elements in place and screwin the inner M14 cylinder head bolts.

� Unscrew and remove the guide studs andscrew in the outer M12 cylinder head bolts.

D2103021

NOTE: Do up the retaining nuts lightly to alignthe cylinder heads.

127.Fit the intake manifold with EGR valveand the old gasket.


10/96 Scorpio ’95 00-01-39

8

10

6

2

43

S2103579

7

21–175

1

30 Nm

5

9

NOTE: Bolt-tightening sequence.

128.Pre-tighten the inner M14 cylinderhead bolts.

8

10

6

2

43

S2103580

21–540

21–175

70

1

70

7

9

5


129.Tighten the inner M14 cylinder headbolts in two stages.

The cylinder head bolts should beretorqued after the engine has reachednormal operating temperature.


10/96 Scorpio ’95 00-01-40

S2103578

3

4

2

30 Nm

21–540

21–002

85

1

NOTE: Bolt tightening sequence.

130.Tighten the outer M12 cylinder headbolts on the injection side in two stages.


S2103581

2

3

4

30 Nm

21–540

21–002

85

1


131.Tighten the outer M12 cylinder headbolts on the exhaust side in two stages.



10/96 Scorpio ’95 00-01-41

D2103521

32 Nm

132.Remove the intake manifold, fit a newintake/exhaust gasket, fit the intakemanifold and tighten the nuts.

S2103534

1

2 27 Nm�CAUTION: Do not turn the engine for 15

minutes.

133.Fit the rocker shafts.

NOTE: Rotate the crankshaft to 20� beforeTDC.

NOTE: Keep to the removal sequence.

1 Insert the push rods.

2 Coat the nuts with hypoid oil SAE 90 andtighten them.

D2103525

69 Nm23–043NOTE: Fit the injector with NLS in the firstcylinder.

134.Fit the injectors.

� Fit new copper sealing rings (1,5 mm thickand 17,5 mm inside diameter) on theinjectors.

� Apply sealer (ESEAM–1C1014) to theinjector threads.

� Install the injectors and new sealing rings.

S2103532

24 Nm

135.Fit the cylinder head cover with a newgasket.


10/96 Scorpio ’95 00-01-42

PZS2103623

13 Nm

136.Fit the rocker arm oil feed pipe usingnew seals.

12 Nm

D2103522

137.Fit the coolant collection pipe with thethermostat housing and new gaskets.

2

D2103518

31 25 Nm

138.Fit the coolant pump.

1 Install the coolant pump with a new gasket.

2 Connect the coolant hose to the thermostathousing.

3 Attach the hose to the bracket.

D2103520

132 Nm

2 27 NmNOTE: The intake and exhaust manifolds usethe same gasket.

139. Install the exhaust manifold with theturbocharger.

1 Tighten the exhaust manifold nuts.

2 Fit the pipe flange to the EGR valve.


10/96 Scorpio ’95 00-01-43

S2103053

140.Fit the turbocharger oil feed pipe to themain bearing housing hollow retainingscrew.

27 Nm

D2103607

141.Fit the coolant pipe with the bracket.

D2103515

15 Nm

142.Fit the smoke pressure limiter (SPL)pipe using new seals.

S2103562

17 Nm

143.Fit the injector pipes and the leak-offpipes.


10/96 Scorpio ’95 00-01-44

D21036051 13 Nm

27 Nm

2

144. Install the oil feed pipe using new seals.

1 Fit the oil feed pipe to the connector usingnew seals.

2 Bracket of oil feed pipe

2

D2103604

47 Nm

1

27 Nm

145.Fit the fuel filter mounting platecomplete with the fuel heater, oilseparator and wiring loom.

NOTE: The bolt holds the CKP sensor cableretaining clip in place.

1 Fit the mounting plate with the bracket of theoil feed pipe (three bolts).

2 Fit the fuel feed pipe using new seals.

1

D2103011

2

146.Join the connectors and install them onthe fuel filter retaining plate.

1 CKP sensor connector

2 NLS connector

D2103010

4

3

5

2

1

147.Connect the plugs to the fuel injectionpump and the fuel heater and fit thewiring loom.

1 Connect the plug of the fuel shut-off valve.

2 Connect the plug of the FLVR sensor.

3 Connect the plug of the pump timingadjusting valve.

4 Connect the plug of the fuel heater.

5 Attach the wiring loom retaining clip to theaccelerator cable bracket.


10/96 Scorpio ’95 00-01-45

IAS2103090

31

2

4

148.Connect the plugs.

1 Engine coolant temperature (ECT) sensorconnector.

2 Coolant temperature gauge senderconnector.

3 Fit the wiring loom retaining clip.

4 Oil pressure switch connector.

Secure the lead using cable ties.

IAS2103577

2

1

27 Nm

149.Connect the fuel return pipe to theinjection pump using new seals.

1 Fuel return pipe to fuel injection pump

2 Attach the fuel pipe retaining clips.

S2103070

2

1

4

3

150.Connect the hoses.

1 Crankcase ventilation hose

2 Oil separator oil return hose to sump.

3 Attach the wiring loom retaining clip.

4 Insert the oil dipstick.


10/96 Scorpio ’95 00-01-46

S2103530

69 Nm

47 Nm

151.Fit the automatic belt tensioner.

S2103531

47 Nm

147 Nm

247 Nm 3

69 Nm

152.Fit the upper alternator bracket with thelower fuel injection pump bracket.

1 Alternator bracket (three bolts).

2 Tighten the bolt and nut on the fuel injectionpump bracket.

3 Fit the engine lifting eye.

27 Nm

28 Nm

2

D2103597

3

1

153.Fit the alternator with the vacuum pump.

1 Screw in the bolts.

2 Fit the oil return pipe.

3 Connect the oil feed pipe to the vacuumpump.

D2103701

47 Nm

154. Install the right-hand engine mountingbracket.


10/96 Scorpio ’95 00-01-47

D2103596

2

21–064

21–150

1

155.Detach the engine from the assemblystand.

1 Detach the mounting bracket.

2 Detach the mounting plate.

60 Nm

D2103606

156. Install the oil filter intermediate housing.

Coat the new O-ring with engine oilSAE 15W40.

S2103565

2 1

157. Install the engine oil filter.

Lubricate the rubber gasket of the newengine oil filter with engine oil SAE 15W40.Screw the oil filter on finger tight.

158.Fit the turbocharger oil return hose tothe cylinder block.

NOTE: The connector must point towards theturbocharger oil return hose.

1 Fit the connector to the cylinder block.

2 Fit the hose to the connector.

D2103700

47 Nm

159.Fit the left-hand engine mountingbracket.


10/96 Scorpio ’95 00-01-48

160.Finishing operations

Turn the engine over three times to checkthere is no contact between the pistonsand the valves.

engine – dismantle and assemble (21 134 8) - ford · pdf file2,5l tci diesel engine...

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